Impression wheel for making respiratory face masks

ABSTRACT

An improved impression wheel for use within respiratory face mask manufacturing machines that includes a first, second, and third series of spaced helicoidal teeth shaped and adapted to more efficiently and securely interconnect respective layers of respiratory face masks.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is related to and claims priority from prior provisional application Ser. No. 63/018,580, filed May 1, 2020 which is incorporated herein by reference.

COPYRIGHT NOTICE

A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. 37 CFR 1.71(d).

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates generally to the field of making respiratory face masks and more specifically to impression wheels used within respiratory face mask manufacturing machines to make respiratory face masks.

2. Description of the Related Art

Previous impression wheels used within respiratory face mask manufacturing machines include a series of spaced teeth that are used to press and interconnect together four side portions of respective layers of respiratory face masks. The resulting face masks usually fall apart over time or require further stitching or other forms of interconnecting that increase the costs of producing the face masks.

Thus, a need exists for an improved impression wheel the results in a stronger and more reliable interconnection between respective layers of respiratory face masks.

BRIEF SUMMARY OF THE INVENTION

In view of the foregoing disadvantages inherent in the production of previous respiratory face masks, the present invention provides an improved impression wheel for use within respiratory face mask manufacturing machines that includes a first, second, and third series of spaced helicoidal teeth shaped and adapted to more efficiently and securely interconnect respective layers of respiratory face masks.

The features of the invention which are believed to be novel are particularly pointed out and distinctly claimed in the concluding portion of the specification. These and other features, aspects, and advantages of the present invention will become better understood with reference to the following drawings and detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The figures which accompany the written portion of this specification illustrate embodiments for the present invention, Improved Protective Face Masks, constructed and operative according to the teachings of the present invention.

FIG. 1 shows a side view of the improved impression wheel according to the preferred embodiment of the present invention.

FIG. 2 shows a perspective view of the improved impression wheel according to the preferred embodiment of the present invention of FIG. 1.

FIG. 3 shows a cut-out view (B) of one of the first series of spaced helicoidal teeth of the improved impression wheel according to the preferred embodiment of the present invention of FIG. 1.

FIG. 4 shows a side view of the improved impression wheel according to the preferred embodiment of the present invention of FIG. 1.

FIG. 5 shows a cross sectional view (C-C) of the improved impression wheel according to the preferred embodiment of the present invention of FIG. 1.

FIG. 6 shows a cut-out view (E) of one of the first series of spaced helicoidal teeth of the improved impression wheel according to the preferred embodiment of the present invention of FIG. 1.

FIG. 7 shows a cut-out view (F) of one of the second series of spaced helicoidal teeth of the improved impression wheel according to the preferred embodiment of the present invention of FIG. 1.

FIG. 8 shows a perspective view of the impression wheel within a known respiratory face mask manufacturing machine.

FIG. 9 shows a schematic side view of wheels and cutters forming a respiratory face mask within the known respiratory face mask manufacturing machine of FIG. 8.

The various embodiments of the present invention will hereinafter be described in conjunction with the appended drawings.

DETAILED DESCRIPTION

As discussed above, embodiments of the present invention relate to an improved impression wheel for use within respiratory face mask manufacturing machines that includes a first, second, and third series of spaced helicoidal teeth shaped and adapted to more efficiently and securely interconnect respective layers of respiratory face masks.

Referring to FIGS. 1-7, the improvement to respiratory face mask manufacturing machines that include a series of wheels, connector mechanisms, and transfer mechanisms adapted to form respiratory face masks, comprises an impression wheel 200 including a main cylindrical body including a length, a width, a perimeter, a central axis; a proximal end section; a distal end section; and an outer surface, wherein the outer surface extends along the length and around the perimeter of the cylindrical body; a first series of spaced helicoidal teeth 210, each including a whole depth, a face width, and a top land, wherein the first series of spaced helicoidal teeth 210 are formed having a slanted tooth trace, and wherein the first series of spaced helicoidal teeth 210 extend from and around the perimeter of the proximal end section of the outer surface of the main cylindrical body; a second series of spaced teeth 220, each including a whole depth equal to the whole depth of the first series of spaced teeth, a face width, and a top land, wherein the second series of spaced helicoidal teeth 220 are formed having a slanted tooth trace equal to the first series of spaced helicoidal teeth, and wherein the second series of spaced helicoidal teeth extend from and around the perimeter of the distal end section of the outer surface of the main cylindrical body; and a third series of spaced teeth 230, each including a whole depth equal to the whole depth of the first series of spaced teeth, a face width, and a top land, wherein the third series of spaced helicoidal teeth are formed having a slanted tooth trace equal to the first series of spaced helicoidal teeth, and wherein the third series of spaced helicoidal teeth extend from and along a substantial portion of the length of the main cylindrical body, and extend between the first and second series of spaced helicoidal teeth, wherein the impression wheel is adapted to press and interconnect together four side portions of respective layers of the respiratory face masks.

The teeth of the first, second, and third series of spaced helicoidal teeth are respectively spaced from one another a distance of 0.32 inches. The slanted tooth trace of the first, second, and third series of spaced helicoidal teeth are formed at a 45 degree angle. The face width of the first series of spaced helicoidal teeth is 0.25 inches, the face width of the second series of spaced helicoidal teeth is 0.125 inches, and the face width of the third series of spaced helicoidal teeth is 0.83 inches. Further, the arc length of the first series of spaced helicoidal teeth is 0.3697 inches, the arc length of the second series of spaced helicoidal teeth is 0.1849 inches, and the arc length of the third series of spaced helicoidal teeth is 1.157 inches. Furthermore, the length of the third series of spaced helicoidal teeth is greater than the distance between the first and second series of spaced helicoidal teeth, to thereby form a pattern of interconnectivity between the four side portions of respective layers of the respiratory face masks that results in one side of the four side portions being interconnected a distance away from an edge of the one side of the respiratory face masks, and wherein a nose piece section is thereby formed along the one side of the four side portions that includes opposite end portions thereof that are interconnected to thereby enclose the nose piece section.

As shown in FIGS. 2 and 5, the impression wheel further may comprise two spaced nose piece members 224 connected to the outer surface of the main cylindrical body adjacent to the second series of spaced helicoidal teeth 220, and are adapted to further enclose the nose piece section. The two spaced nose piece members 224 may be spaced at an angle X of 235.37 degrees apart or angle Y of 290 degrees apart depending on the requirements of the respiratory face masks being produced.

The impression wheel further comprises a first cylindrical connector 250 including a length, a width, a perimeter, a central axis, a proximal end section, and a distal end section, wherein the proximal end section is connected to and extends from the proximal and section of the main cylindrical body, wherein the central axis is coaxial with the central axis of the main cylindrical body, and wherein the first cylindrical connector is adapted to connect with and be rotated by rotary members within the respiratory face mask manufacturing machine, to thereby rotate the impression wheel; and a second cylindrical connector 260 including a length, a width, a perimeter, a central axis, a proximal end section, and a distal end section, wherein the proximal end section is connected to and extends from the distal and section of the main cylindrical body, wherein the central axis is coaxial with the central axis of the main cylindrical body, and wherein the second cylindrical connector is adapted to connect with and be rotated by rotary members within the respiratory face mask manufacturing machine, to thereby rotate the impression wheel.

The first cylindrical connector 250 further includes a first section 251 including a proximal end, a distal end, and a width, wherein the first section is formed having a width smaller than the width of the main cylindrical body, and wherein the proximal end is attached to the proximal end section of the main cylindrical body; and a second section 253 including a proximal end, a distal end, and a width, wherein the second section is formed having a width smaller than the width of the first section, and wherein the proximal end is attached to the distal end of the first section.

The second cylindrical connector 260 further includes a first section 261 including a proximal end, a distal end, and a width, wherein the first section is formed having a width smaller than the width of the main cylindrical body, and wherein v proximal end is attached to the distal end section of the main cylindrical body; and a second section 263 including a proximal end, a distal end, and a width, wherein the second section is formed having a width smaller than the width of the first section, and wherein the proximal end is attached to the distal end of the first section; and a third section 265 including a proximal end, a distal end, and a width, wherein the third section is formed having a width smaller than the width of the second section, and wherein the proximal end is attached to the distal end of the second section. The third section 265 of the second cylindrical connector 260 includes an elongated slot 267, wherein the elongated slot 267 extends from the proximal end to the distal end and is adapted to form a more secure connection between the impression wheel 200 and the rotary members within the respiratory face mask manufacturing machine.

The impression wheel 200 may formed from a material chosen from a group of materials consisting of steel, ceramic, aluminum, and copper.

The following is a list of dimensions correlating to the reference numbers in FIGS. 1-7:

-   -   (10): 9.7341 inches (247.25 millimeters)     -   (20): 3.9370 inches (100.00 millimeters)     -   (30): 0.5000 inches (12.70 millimeters)     -   (40): 0.1400 inches (3.56 millimeters)     -   (50): 0.1250 inches (3.18 millimeters)     -   (60): 3.187 inches (80.95 millimeters)     -   (70): 0.3750 inches (9.53 millimeters)     -   (80): 0.4643 inches (11.79 millimeters)     -   (90): 3.9764 inches (101.00 millimeters)     -   (100): 2.6181 inches (66.50 millimeters)     -   (110): 1.3583 inches (34.50 millimeters)     -   (120): 1.2598 inches (32.00 millimeters)     -   (130): 0.9843 inches (25.00 millimeters)     -   (140): 1.259 inches (31.98 millimeters)     -   (150): 0.83 inches (21.13 millimeters)     -   (160): 0.2362 inches (6.00 millimeters)     -   (170): 0.7871 inches (19.99 millimeters)     -   (181): 0.01 inches (0.254 millimeters)     -   (182): 0.021 inches (0.533 millimeters)     -   (183): 0.032 inches (0.813 millimeters)     -   (184): 0.048 inches (1.216 millimeters)     -   (185): 0.016 inches (0.406 millimeters)     -   (186): 0.01 inches (0.254 millimeters)     -   (215): 0.250 inches (6.35 millimeters)     -   (225): 0.125 inches (3.18 millimeters)

FIGS. 8 and 9 show a known respiratory face mask manufacturing machine including a non-woven fabric wheel 1, a nose piece wheel 2, a nose wheel cutter 3, a sonic mask print wheel 4, a non-woven fabric pressing wheel 5, a folding section 6, a mask cutting wheel 7, and a sonic wheel 9 for forming a known respiratory face mask 8. The improvement therein has been set forth and described above, wherein the improved impression wheel 200 replaces the known sonic mask print wheel 4 within the respiratory face mask manufacturing machine.

The embodiments of the invention described herein are exemplary and numerous modifications, variations and rearrangements can be readily envisioned to achieve substantially equivalent results, all of which are intended to be embraced within the spirit and scope of the invention. Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientist, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. 

What is claimed:
 1. In a respiratory face mask manufacturing machine including a series of wheels, connector mechanisms, and transfer mechanisms adapted to form respiratory face masks, the improvement comprising: an impression wheel including: a main cylindrical body including: a length; a width; a perimeter; a central axis; a proximal end section; a distal end section; and an outer surface; wherein said outer surface extends along said length and around said perimeter of said cylindrical body; a first series of spaced helicoidal teeth, each including: a whole depth; a face width; and a top land; wherein said first series of spaced helicoidal teeth are formed having a slanted tooth trace; and wherein said first series of spaced helicoidal teeth extend from and around said perimeter of said proximal end section of said outer surface of said main cylindrical body; a second series of spaced teeth, each including: a whole depth equal to said whole depth of said first series of spaced teeth; a face width; and a top land; wherein said second series of spaced helicoidal teeth are formed having a slanted tooth trace equal to said first series of spaced helicoidal teeth; and wherein said second series of spaced helicoidal teeth extend from and around said perimeter of said distal end section of said outer surface of said main cylindrical body; and a third series of spaced teeth, each including: a whole depth equal to said whole depth of said first series of spaced teeth; a face width; and a top land; wherein said third series of spaced helicoidal teeth are formed having a slanted tooth trace equal to said first series of spaced helicoidal teeth; and wherein said third series of spaced helicoidal teeth extend from and along a substantial portion of said length of said main cylindrical body, and extend between said first and second series of spaced helicoidal teeth; wherein said impression wheel is adapted to press and interconnect together four side portions of respective layers of said respiratory face masks.
 2. The improvement of claim 1, wherein said teeth of said first, second, and third series of spaced helicoidal teeth are respectively spaced from one another a distance of 0.32 inches.
 3. The improvement of claim 1, wherein said slanted tooth trace of said first, second, and third series of spaced helicoidal teeth are formed at a 45 degree angle.
 4. The improvement of claim 1, wherein: said face width of said first series of spaced helicoidal teeth is 0.25 inches; said face width of said second series of spaced helicoidal teeth is 0.125 inches; and said face width of said third series of spaced helicoidal teeth is 0.83 inches.
 5. The improvement of claim 1, wherein: said arc length of said first series of spaced helicoidal teeth is 0.3697 inches; said arc length of said second series of spaced helicoidal teeth is 0.1849 inches; and said arc length of said third series of spaced helicoidal teeth is 1.157 inches.
 6. The improvement of claim 1, wherein the length of said third series of spaced helicoidal teeth is greater than the distance between said first and second series of spaced helicoidal teeth, to thereby form a pattern of interconnectivity between said four side portions of respective layers of said respiratory face masks that results in one side of said four side portions being interconnected a distance away from an edge of said one side of said respiratory face masks, and wherein a nose piece section is thereby formed along said one side of said four side portions that includes opposite end portions thereof that are interconnected to thereby enclose said nose piece section.
 7. The improvement of claim 1, wherein said impression wheel is formed from a material chosen from a group of materials consisting of steel, ceramic, aluminum, and copper.
 8. The improvement of claim 6, wherein said impression wheel further comprises: two spaced nose piece members; wherein said two spaced nose piece members are connected to said outer surface of said main cylindrical body adjacent to said second series of spaced helicoidal teeth, and are adapted to further enclose said nose piece section.
 9. The improvement of claim 8, wherein said two spaced nose piece members are spaced 235.37 degrees apart.
 10. The improvement of claim 8, wherein said two spaced nose piece members are spaced 290 degrees apart.
 11. The improvement of claim 1, wherein said impression wheel further comprises: a first cylindrical connector including: a length; a width; a perimeter; a central axis; a proximal end section; a distal end section; wherein said proximal end section is connected to and extends from said proximal and section of said main cylindrical body; wherein said central axis is coaxial with said central axis of said main cylindrical body; and wherein said first cylindrical connector is adapted to connect with and be rotated by rotary members within said respiratory face mask manufacturing machine, to thereby rotate said impression wheel; and a second cylindrical connector including: a length; a width; a perimeter; a central axis; a proximal end section; a distal end section; wherein said proximal end section is connected to and extends from said distal and section of said main cylindrical body; wherein said central axis is coaxial with said central axis of said main cylindrical body; and wherein said second cylindrical connector is adapted to connect with and be rotated by rotary members within said respiratory face mask manufacturing machine, to thereby rotate said impression wheel.
 12. The improvement of claim 11, wherein said first cylindrical connector further includes: a first section including: a proximal end; a distal end; and a width; wherein said first section is formed having a width smaller than said width of said main cylindrical body; and wherein said proximal end is attached to said proximal end section of said main cylindrical body; and a second section including: a proximal end; a distal end; and a width; wherein said second section is formed having a width smaller than said width of said first section; and wherein said proximal end is attached to said distal end of said first section.
 13. The improvement of claim 11, wherein said second cylindrical connector further includes: a first section including: a proximal end; a distal end; and a width; wherein said first section is formed having a width smaller than said width of said main cylindrical body; and wherein said proximal end is attached to said distal end section of said main cylindrical body; and a second section including: a proximal end; a distal end; and a width; wherein said second section is formed having a width smaller than said width of said first section; and wherein said proximal end is attached to said distal end of said first section; and a third section including: a proximal end; a distal end; and a width; wherein said third section is formed having a width smaller than said width of said second section; and wherein said proximal end is attached to said distal end of said second section.
 14. The improvement of claim 13, wherein said third section of said second cylindrical connector includes: an elongated slot: wherein said elongated slot extends from said proximal end to said distal end and is adapted to form a more secure connection between said impression wheel and said rotary members within said respiratory face mask manufacturing machine. 